Furnace Repair (Online)

Furnace Repair (Online) at a Major Petrochemical Plant in Malaysia

Challenges

Since the hotspot was rapidly growing it was a critical situation for the client to take a decision from the options available. In such a situation KLAY EnerSol had to ensure the material and specialist crew can be mobilized on short notice from Netherlands.

In the end client decided on a short emergency shutdown plus online hotspot repair as the most efficient option and KLAY EnerSol did the needful.

How Online Hotspot Repair Help

The Online Hotspot Repair helped to avoid a shutdown which could last at least 2 weeks to shutdown, scaffold, repair and start-up.

In this case the furnace was shutdown for only 3 days to replace the burnt plates. This was replaced without man-entry from outside the furnace which left gaps between new and old insulation as expected.

Once the plant started KLAY EnerSol and Insulcon did the Online Hotspot Repair. This was done by pushing custom-designed umbrellas through small holes to bridge the gaps while Insulmould (slurry) was pumped to fill the gaps between the old and new insulation.

“Client was pleased with the services provided by Insulcon and KLAY EnerSol that helped to reduce the duration of emergency shutdown for repair of hotspot.”

Executive Summary

The client was experiencing a rapidly growing hotspot on their Reformer Furnace due to collapse of a large section of modules. The client shut down the reformer for 3 days for emergency repair (without man-entry) and contracted KLAY EnerSol to repair the gaps between new and old insulation after start-up of Reformer Furnace.

  • Furnace shut-down for 3 days for emergency repair without man-entry to reduce shutdown window.
  • KLAY EnerSol contracted to repair gaps between old and new insulation after the start-up of Reformer Furnace.
  • The repair of gaps (hotspots) was completed within 3 days while the furnace was operating.

 

Results, Return on Investment and Future Plans

The Online Hotspot Repair successfully sealed the gaps that were left after replacing the burnt plates. As a result, the repair was done with only 3 days of shut down without man-entry.

Online Hotspot Repair avoided a shutdown that could last at least 2 weeks to shutdown, scaffold, repair and start-up. With an estimated loss of RM 700,000 for each day of shut down.

Further details are available in the Online Hot Spot Repair Report


 Furnace Repair (Online)

Furnace Repair (Online) at a Major Petrochemical Plant in Malaysia

Executive Summary

The client was experiencing a rapidly growing hotspot on their Reformer Furnace due to collapse of a large section of modules. The client shut down the reformer for 3 days for emergency repair (without man-entry) and contracted KLAY EnerSol to repair the gaps between new and old insulation after start-up of Reformer Furnace.

  • Furnace shut-down for 3 days for emergency repair without man-entry to reduce shutdown window.
  • KLAY EnerSol contracted to repair gaps between old and new insulation after the start-up of Reformer Furnace.
  • The repair of gaps (hotspots) was completed within 3 days while the furnace was operating.

Results, Return on Investment and Future Plans

The Online Hotspot Repair successfully sealed the gaps that were left after replacing the burnt plates. As a result, the repair was done with only 3 days of shut down without man-entry.

Online Hotspot Repair avoided a shutdown that could last at least 2 weeks to shutdown, scaffold, repair and start-up. With an estimated loss of RM 700,000 for each day of shut down.

Further details are available in the Online Hot Spot Repair Report

“Client was pleased with the services provided by Insulcon and KLAY EnerSol that helped to reduce the duration of emergency shutdown for repair of hotspot.”

Challenges

Since the hotspot was rapidly growing it was a critical situation for the client to take a decision from the options available. In such a situation KLAY EnerSol had to ensure the material and specialist crew can be mobilized on short notice from Netherlands.

In the end client decided on a short emergency shutdown plus online hotspot repair as the most efficient option and KLAY EnerSol did the needful.

How Online Hotspot Repair Help

The Online Hotspot Repair helped to avoid a shutdown which could last at least 2 weeks to shutdown, scaffold, repair and start-up.

In this case the furnace was shutdown for only 3 days to replace the burnt plates. This was replaced without man-entry from outside the furnace which left gaps between new and old insulation as expected.

Once the plant started KLAY EnerSol and Insulcon did the Online Hotspot Repair. This was done by pushing custom-designed umbrellas through small holes to bridge the gaps while Insulmould (slurry) was pumped to fill the gaps between the old and new insulation.